oil cooler rebuild kit: 3C3Z-6A642-CA This literally just went up in price again, it's $269 now

intake manifold gaskets, may not be necessary, but cheap and you'll kick yourself if you do end up needing them. There's a few kits on ebay that are in the $70-$90 price range that have TONS of gaskets/o-rings in them, and the intake manifold gaskets are included, here's one: FORD POWERSTROKE 6.0 DIESEL INTAKE GASKET SET 03-08 | eBay

and egr delete, also found on ebay, relatively cheap these days. Easily found under $200, just try and fine one with a new solid up-pipe would be my suggestion. For instance, here's one for $91 buy it now... dang! FORD F250 2003-2007 6.0L EGR BYPASS and DELETE KIT POWERSTROKE DIESEL | eBay

 

It may be cheaper to peice it together. Tousley has best price on oil coolers, I bought EGR delete off of ebay for less than $150. SCTs are pretty standard at $379 new. I also have a Sinister coolant filter.

As far as intake gaskets go, at 101k, mine could have been reused, but I bought new to play it safe. They're kinda like plastic with rubber grommets around fasteners.

MKM sells it all in a kit, but they want too much for their EGR delete IMO.

 

Mdub beat me... I don't care for the straight block off kits. They used to leak alittle but, I hear they have gotten better. I have alot of parts waiting for a wrench at home. I like to think I'm handy so I opt'ed for a 29mm and 34mm steel freeze plug. Local welder told me $20 and he will weld them in... Others have said you can buy 30mm and 35mm and just hit them in tight with a hammer. I'M NOT THAT CHEAP. Aparentely it works??? There are a few companies that sell the stock egr already welded up for $350. I bought a set of intake gaskets to change out as a butt saver. I wouldn't want to finish then relize that $40 (20 each at tousley) could have saved my bacon! I payed $279 for a oil cooler from them too same part # as above. I thought changing out the STC fitting would be a good way to help my HPOP live as long as it can ($60). Blue spring kit $70 (you can buy just the spring for $20 on-line somewhere). While I was ordering I got bango bolts and washers too ($30 Totally not needed but, part of the cool guy club requirements). I got a coolant filter kit and fuel pressure adapter from DFUSER for $150. Autoparts store, two steel freeze plugs $4 and a $5 stant radiator (degas) cap. Now, alot of guys say change stand pipes and dummy plugs while your that close but, I disagree. In '05 they upgraded to the D-style and I don't want to mess with anything under the vavle covers unless I absolutely have to.
Gauges... Mechanical are by far the best way to go. I (mostly the little lady) don't want a pillar on the family truckster so I did the SG2. It works great for what THIS car needs to do. It can monitor alot of things so, I saw it as a tool too. That being said, the F-650 dash mod with a hand full of gauges looks SO TRICK when they roll into the shop! If your towing heavy an EGT gauge is a must. I used the $8 fuel adapter listed above, a couple of fittings laying around, and an old oil pressure gauge to check my fuel pressure under the hood. I'm not running a super hot tune so, I'm not worried about running low on pressure and now I can screw it in anytime I want to check.

I got everything for less than $600... Now, if I could buy some time to finish the job!!!

 

I just got a set of Felpro intake gaskets from Advance Auto parts $46 for complete set, has the orings for oil filter housing and erg cooler and bypass hose, donut for top of water pump housing, Nice gaskets

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C-tane, you are alot better off using the 35mm and 30mm freeze plugs, they will tap right in and then they can be tacked or fully welded. You get a much better weld when there is no gap to begin with, it will be a pain in the butt to try to weld a smaller one in there whithout it being snug to hold itself in there, plus if the weld is not perfect it won't leak with the larger plugs

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C-tane, you are alot better off using the 35mm and 30mm freeze plugs, they will tap right in and then they can be tacked or fully welded. You get a much better weld when there is no gap to begin with, it will be a pain in the butt to try to weld a smaller one in there whithout it being snug to hold itself in there, plus if the weld is not perfect it won't leak with the larger plugs

 

Definitely weld the plugs if you put them in. The one on the exhaust side, you need to fully weld and fill the whole are with weld, the little freeze plug wont hold up to extreme heat when you get running the hot tunes. It will melt. You can also buy stainless plugs that fit in there that you can have welded too, from ebay etc.

 

If someone was going to plug it and had an '05my engine it would be a good idea to cut out the deflector from inside the up pipe as well...

 

Anyone know anything bout the dormon oil coolers? I'm going to start ordering parts and these are on eBay about $80-$100 cheaper than the ford. Are they not as good or is it just because the others say ford? And I will definitely be buying an egr delete kit not trying to make my own. Gonna get one of the eBay kits there as well.

 

Are you talking about the egr cooler here or the oil cooler? They're two completely different things.

I know a few guys on the other boards have them, haven't really heard anything about them though. They are quite a bit cheaper than Ford one's. You can get the Ford one from Tousley for $269 though...